Stiff discrete insert array for thermal ptr management with desired induced stress state that reduces tendency for write pole erasure

ABSTRACT

Embodiments of the present invention generally relate to a magnetic device having a discontinuous array of columns disposed near a magnetic pole. Each column has a length extending perpendicular to an air bearing surface and a width. The length is greater than the width.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of co-pending U.S. patent applicationSer. No. 14/012,310, filed Aug. 28, 2013, which patent application isherein incorporated by reference.

BACKGROUND

1. Field

Embodiments of the present invention generally relate to magnetic datarecording, and more particularly to a structure for preventing poleerasure and thermally induced pole tip deformation in a write head.

2. Description of the Related Art

The heart of a computer is a magnetic disk drive which typicallyincludes a rotating magnetic disk, a slider that has read and writeheads, a suspension arm above the rotating disk and an actuator arm thatswings the suspension arm to place the read and/or write heads overselected circular tracks on the rotating disk. The suspension arm biasesthe slider towards the surface of the disk when the disk is not rotatingbut, when the disk rotates, air is swirled by the rotating disk adjacentan air bearing surface (ABS) of the slider causing the slider to ride onan air bearing a slight distance from the surface of the rotating disk.When the slider rides on the air bearing, the write and read heads areemployed for writing magnetic impressions to and reading magnetic signalfields from the rotating disk. The read and write heads are connected toprocessing circuitry that operates according to a computer program toimplement the writing and reading functions.

Most recently researchers have focused on the development ofperpendicular magnetic recording (PMR) systems in order to increase thedata density of a recording system. Such perpendicular recording systemsrecord magnetic bits of data in a direction that is perpendicular to thesurface of the magnetic medium. A write head used in such a systemgenerally includes a write pole having a relatively small cross sectionat the ABS and a return pole having a larger cross section at the ABS. Amagnetic write coil induces a magnetic flux to be emitted from the writepole in a direction generally perpendicular to the plane of the magneticmedium. This flux returns to the write head at the return pole where theflux is sufficiently spread out and weak that the flux does not erasethe signal written by the write pole.

In order to meet ever increasing demand for improved data rate and datacapacity, researchers are constantly seeking ways to make read and writeheads smaller while increasing the write field produced by such writeheads. Increasing the overwrite field requires increasing the currentflow through the write coil. Decreasing the size of the write headrequires decreasing the size of the write coil (decreasing the crosssectional area of the turns of the coil), which increases the electricalresistance of the coil.

This decrease in size and increase in write current greatly increasesthe amount of heat generated by the write head during use. This heatcauses unwanted thermal expansion of the write head, which can result incatastrophic deformation of the write head structure. This deformationis especially problematic in current and future magnetic heads, wherethe fly height of the head is exceedingly small, on the order ofnanometers. The thermal protrusion of the write head, combined withthese low fly heights can result in catastrophic head disk contactduring use. To reduce the thermal protrusion of the write head, a stiffplate with low coefficient of thermal expansion (CTE) has been used toprovide constraint for thermal pole tip protrusion (PTR). However, suchmethod fundamentally utilizes stress transfer from the stiff insert tothe rest of the head. As such, the generation of stresses may alsoaffect the main pole magnetic properties due to relative large positivemagnetostriction effect of CoFe alloys currently being used. Thestresses generated may favor a magnetization state such that itsorientation may align unfavorably causing high remanence and unintendedpole erasure by the write head. Therefore, an improved magnetic devicehaving a reduced tendency for write pole erasure is needed when managingPTR through stress transfer.

SUMMARY OF THE INVENTION

The embodiments of the present invention generally relate to a magneticdevice having a discontinuous array of columns disposed near a magneticpole. Each column has a length extending perpendicular to an air bearingsurface and a width. The length is greater than the width.

In one embodiment, a magnetic head is disclosed. The magnetic headincludes a write pole extending to an air bearing surface and adiscontinuous array of columns aligned in a cross-track direction anddisposed over the write pole. Each column has a length extendingperpendicular to the air bearing surface and a width. The length isgreater than the width.

In another embodiment, a magnetic head is disclosed. The magnetic headincludes a discontinuous array of columns, a dielectric materialdisposed between and over the discontinuous array of columns, a readhead disposed over the dielectric material, and a write head disposedover the read head.

In another embodiment, a method for forming a magnetic head isdisclosed. The method includes depositing and forming a write pole overa substrate, encapsulating the write pole with insulating dielectricmaterial such as alumina, and depositing and forming an insert layerover the write pole, removing portions of the insert layer to form adiscontinuous array of columns by liftoff or by masking-and-etch, anddepositing a fill material between the discontinuous array of columns.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 illustrates a disk drive system, according to an embodiment ofthe invention.

FIGS. 2A-2B illustrate a side view of a magnetic device according toembodiments of the invention.

FIG. 3 is a cross sectional view of a magnetic head from an ABSaccording to one embodiment of the invention.

FIG. 4 is a cross sectional view of a magnetic head from the ABSaccording to one embodiment of the invention.

FIG. 5 shows a plate and a write pole of a conventional magnetic head.

FIG. 6 shows a discontinuous array of columns and a write pole of amagnetic head according to embodiments of the invention.

FIG. 7 is a flow diagram of a method for forming a magnetic headaccording to one embodiment of the invention.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements disclosed in oneembodiment may be beneficially utilized on other embodiments withoutspecific recitation.

DETAILED DESCRIPTION

In the following, reference is made to embodiments of the invention.However, it should be understood that the invention is not limited tospecific described embodiments. Instead, any combination of thefollowing features and elements, whether related to differentembodiments or not, is contemplated to implement and practice theinvention. Furthermore, although embodiments of the invention mayachieve advantages over other possible solutions and/or over the priorart, whether or not a particular advantage is achieved by a givenembodiment is not limiting of the invention. Thus, the followingaspects, features, embodiments and advantages are merely illustrativeand are not considered elements or limitations of the appended claimsexcept where explicitly recited in a claim(s). Likewise, reference to“the invention” shall not be construed as a generalization of anyinventive subject matter disclosed herein and shall not be considered tobe an element or limitation of the appended claims except whereexplicitly recited in a claim(s).

The embodiments of the present invention generally relate to a magneticdevice having a discontinuous array of columns disposed adjacent to amagnetic pole. Each column has a length extending at an angle to the ABSsurface preferably perpendicular to the ABS and the cross section areaof these discrete columns parallel to the ABS is much smaller than thetotal surface area of the column. Another way of describing suchgeometry is that the aspect ratio of length vs. width or thickness ofthe columns is much greater than one.

FIG. 1 illustrates a disk drive 100 embodying this invention. As shown,at least one rotatable magnetic disk 112 is supported on a spindle 114and rotated by a disk drive motor 118. The magnetic recording on eachdisk is in the form of annular patterns of concentric data tracks (notshown) on the magnetic disk 112.

At least one slider 113 is positioned near the magnetic disk 112, eachslider 113 supporting one or more magnetic head assemblies 121. As themagnetic disk rotates, the slider 113 moves radially in and out over thedisk surface 122 so that the magnetic head assembly 121 may accessdifferent tracks of the magnetic disk 112 where desired data is written.Each slider 113 is attached to an actuator arm 119 by way of asuspension 115. The suspension 115 provides a slight spring force whichbiases the slider 113 towards the disk surface 122. Each actuator arm119 is attached to an actuator means 127. The actuator means 127 asshown in FIG. 1 may be a voice coil motor (VCM). The VCM comprises acoil movable within a fixed magnetic field, the direction and speed ofthe coil movements being controlled by the motor current signalssupplied by control unit 129.

During operation, the rotation of the magnetic disk 112 generates an airbearing between the slider 113 and the disk surface 122 which exerts anupward force or lift on the slider 113. The air bearing thuscounter-balances the slight spring force of suspension 115 and supportsslider 113 slightly above the disk 112 surface by a small, substantiallyconstant spacing during normal operation.

The various components of the disk drive 100 are controlled in operationby control signals generated by control unit 129, such as access controlsignals and internal clock signals. Typically, the control unit 129comprises logic control circuits, storage means and a microprocessor.The control unit 129 generates control signals to control various systemoperations such as drive motor control signals on line 123 and headposition and seek control signals on line 128. The control signals online 128 provide the desired current profiles to optimally move andposition slider 113 to the desired data track on disk 112. Write andread signals are communicated to and from write and read heads on theassembly 121 by way of recording channel 125.

The above description of a typical magnetic disk storage system and theaccompanying illustration of FIG. 1 are for representation purposesonly. It should be apparent that disk storage systems may contain alarge number of disks and actuators, and each actuator may support anumber of sliders.

FIG. 2A illustrates a side view of a magnetic head 202 according to oneembodiment of the invention. The magnetic head 202 includes a read head204 and a write head 206. The read head 204 includes a magnetoresistivesensor 208, which can be a giant magnetoresistance (GMR), tunnelmagnetoresistive (TMR), or some other type of sensor. Themagnetoresistive sensor 208 is located between first and second magneticshields 210, 212.

The write head 206 includes a magnetic write pole 214 and a magneticreturn pole 216. The write pole 214 can be formed upon a magneticshaping layer 220, and a magnetic back gap layer 218 magneticallyconnect the write pole 214 and the shaping layer 220 with the returnpole 216 at a location removed from the ABS. A write coil 222 (shown incross section in FIG. 2A) passes between the write pole 214, the shapinglayer 220, and the return pole 216, and may also pass above the writepole 214 and the shaping layer 220. The write coil 222 can be a helicalcoil or can be one or more pancake coils. The write coil 222 can beformed upon an insulation layer 224 and can be embedded in a coilinsulation layer 226 such as alumina and or hard baked photoresist.

During operation, an electrical current flowing through the write coil222 induces a magnetic field that causes a magnetic flux to flow throughthe return pole 216, back gap layer 218, shaping layer 220, and writepole 214. This causes a magnetic write field to be emitted from the tipof the write pole 214 toward a magnetic medium 232. The write pole 214has a cross section at the ABS that is much smaller than the crosssection of the return pole 216 at the ABS. Therefore, the magnetic fieldemitting from the write pole 214 is sufficiently dense and strong thatthe write pole 214 can write a data bit to a magnetically hard top layer230 of the magnetic medium 232. The magnetic flux then flows through amagnetically soft underlayer 234, and returns back to the return pole216, where the magnetic flux is sufficiently spread out and too weak toerase the data bit recorded by the write pole 214. A magnetic pedestal236 may be provided at the ABS and attached to the return pole 216 toprevent stray magnetic fields from the write coil 222 from affecting themagnetic signal recorded to the magnetic medium 232.

In order to increase write field gradient, and therefore increase thespeed with which the write head 206 can write data, a trailing,wrap-around magnetic shield 238 may be provided. The magnetic shield 238is separated from the write pole 214 by a non-magnetic layer 239. Themagnetic shield 238 attracts the magnetic field from the write pole 214,which slightly cants the angle of the magnetic field emitting from thewrite pole 214. This canting of the magnetic field increases the speedwith which magnetic field polarity can be switched by increasing thefield gradient. A trailing magnetic return pole 240 can be provided andcan be magnetically connected with the magnetic shield 238. Therefore,the trailing return pole 240 can magnetically connect the magneticshield 238 with the back portion of the write pole 214, such as with theback end of the shaping layer 220 and with the back gap layer 218. Themagnetic shield 238 is also a second return pole so that in addition tomagnetic flux being conducted through the medium 232 to the return pole216, the magnetic flux also flows through the medium 232 to the trailingreturn pole 240. Disposed on the trailing return pole 240 is adiscontinuous array of columns 250 (sometimes referred to as prisms,described in detail below). The location of the discontinuous array ofcolumns 250 is not limited to above the write pole 214. In oneembodiment, the discontinuous array of columns 250 is disposed below thefirst magnetic shield 210, as shown in FIG. 2B.

FIG. 3 is a cross sectional view of a magnetic head 300 from the ABSaccording to one embodiment of the invention. The write pole 214 isdisposed over the insulating layer 226. An insulating material 302 isdisposed adjacent the write pole 214. Over the write pole 214 and theinsulating material 302 are write head structures 303 including thenon-magnetic layer 239, the wrap-around shield 238, and the trailingreturn pole 240. These elements are not shown in FIG. 3 but are commonlyknown features in a PMR recording head. The elements are embedded in thedielectric fill material such as alumina (Al₂O₃). A thick layer of lowCTE material such as silicon carbide (SiC) may be deposited over thewrite head structures 303. Such thick SiC insert may bephotolithographically patterned such that a plurality of periodicallyrepeating columns 250 is formed. The discrete SiC columns 250 may beformed by reactive ion etching (RIE). Another insulating material 304 isdeposited between and over the columns 250.

The distance between the columns 250 will be dictated by the ability todeposit the insulating material 304 into the opening between the columns250 without voids and defects. The insulating layer 226 and theinsulating materials 302, 304 may be Al₂O₃ and the columns 250 may be astiff material having low CTE such as SiC, tungsten (W) or a combinationthereof. Each column 250 has a rectangular or square cross sectionparallel to the ABS. These columns 250 may be recessed from the ABS forhead disk material compatibilities. The sides of the rectangular orsquare cross section of each column 250, such as the width and thethickness of the cross section, are less than a length of the column 250extending perpendicular to the ABS (into the paper). A parameter thatdescribes such property is aspect ratio. The length to width orthickness aspect ratio of the columns 250 is much greater than 1. Thelarger the aspect ratio, the higher the anisotropy of the propertiesthat are of interest, as described below. The columns 250 are aligned ina cross-track direction, indicated by arrows “C.”

FIG. 3 illustrates the discontinuous array of columns 250 that is formedabove the write pole 214 and the generalized write head structures 303for stress generation purposes, as an example. However, the location ofthe columns 250 is generally near a heat source during recording (suchas above coil 222 in FIG. 2A). Certain structures between the columns250 and the write pole 214 shown in FIGS. 2A, 2B are omitted in FIG. 3for ease of understanding of the main pole stress generation. FIG. 4illustrates a magnetic head 400 having a discontinuous array of columns402 disposed below the write pole 214. Again the fine structures inbetween the columns 402 and the write pole 214 are not shown in detailfor ease of understanding the main pole stress generation.

As shown in FIG. 4, the write pole 214 is disposed between the writehead structures 303 and elements 403. Elements 403 may include theinsulating layer 226, the magnetic pedestal 236, the return pole 216 andthe read head 204. Formed below the elements 403 is the discontinuousarray of columns 402 which is embedded in a dielectric material 404.Again the fill material 404 may be Al₂O₃ and the columns 402 may be SiCor W. As described in FIG. 3, each column 402 has a rectangular orsquare cross section parallel to the ABS. The width and the thickness ofthe cross section are less than a length of the column 402 extendingperpendicular to the ABS (into the paper). The way to make the embeddedcolumns 402 and the dielectric material 404 without affecting theexisting manufacturing process is, by commonly known processes, topattern a blank insert film such as SiC and W and RIE the blank insertinto desired shape as described, fill the gaps between the columns withdielectric insulation such as alumina and CMP the top surface flat. Theread head and write head structures can then be built thereon.

The functions of the discontinuous array of columns 250 or 402 areconceptually illustrated in FIGS. 5 and 6. It is to be known that theactual head structure is much more complicated than what is shown inFIGS. 5 and 6. FIGS. 5 and 6 only show two relevant elements (the mainpole in a simplified form and the discrete columns). The purpose ofthese diagrams is to highlight the concept, and the diagrams are anoversimplification for design purposes. For a more complete structure ofa typical recording head, FIGS. 2A and 2B are to be referenced. FIG. 5illustrates a write pole 502 and a conventional insert layer 504 (allother head features are omitted in the diagram to highlight physicalinteractions between the two elements). The write pole 502 may be thewrite pole 214. The conventional insert layer 504 is made of a stiffmaterial in the form of a plate, which has a width (W₁), a thickness(T₁) and a length (L₁). The width is substantially greater than thethickness. The thickness and the width form a rectangle at the ABS andthe length extends perpendicular to the ABS or substantially close tothe ABS without exposing to the ABS. The conventional insert layer 504induces a biaxial compressive stress in the write pole 502, indicated byarrows σx and σy, at a location away from the ABS. The stress σy helpsto manage PTR. However, at the ABS, the conventional insert layer 504exerts uniaxial σx, while the stress σy becomes zero because of the freesurface at the ABS. The uniaxial compressive stress σx at the ABSincreases the squareness of the magnetic (BH) loop, and in turnincreases the tendency for pole erasure.

FIG. 6 shows a write pole 602 and a discontinuous array of columns 604.Again other elements such as insulating layers are omitted for betterillustration. The write pole 602 may be the write pole 214. As shown inFIG. 6, a plurality of columns 604 are disposed spaced apart over thewrite pole 602. Each column 604 has a width (W₂), a thickness (T₂), anda length (L₂). The cross section of the columns 604 may be a square or arectangle. The width W₂ is substantially smaller than the width W₁ andthe length L₂ is substantially greater than the width W₂. Thediscontinuous array of columns 604 induces substantially smaller stressσx while the stress σy remains similar in magnitude. The compressivestress σy that helps to manage PTR does not change, while the stress σxinduced by the columns 604 will be substantially reduced throughout thedepth of the columns 604 compared to the stress σx induced by thecontinuous insert plate 504. This is due to the fact that the columns604 are discontinuous and have a small dimension in the cross-trackdirection, leading to a minimal generation of compressive stress σx inthe write pole 602. A smaller compressive stress exerted on the writepole 602 at the ABS reduces the tendency for pole erasure. Moreimportantly, a main pole with uniaxially compressive stressperpendicular to ABS (σy) throughout the main pole helps the alignmentof the easy axis parallel to ABS for CoFe that has a positivemagnetostriction. Such magnetic configuration is known to help in easingpole erasure.

FIG. 7 is a flow diagram of a method 700 for forming a magnetic headaccording to one embodiment of the invention. The method 700 starts atstep 702 with depositing an insulating layer over a substrate. Thesubstrate may be composed of a non-magnetic material and may include oneor more components of a magnetic head, such as a read sensor, shield,heaters, coils etc. The insulating layer may be composed of anon-magnetic material such as Al₂O₃ and may be deposited by any suitabledeposition method such as chemical vapor deposition (CVD), atomic layerdeposition (ALD) or physical vapor deposition (PVD). Only steps relevantto the making of the insert are shown.

Next, at step 704, an insert layer is deposited over the insulatinglayer. The insert layer may be composed of a stiff material with low CTEsuch as SiC or W and may be deposited by any suitable deposition methodsuch as CVD or PVD. At step 706, portions of the insert layer areremoved by photolithography methods known to those skilled in the art,forming a discontinuous array of columns over the insulating layer. Theremoval process may be any suitable removal process, such as reactiveion etching (RIE). Last, at step 708, a fill material is depositedbetween the columns. The fill material may be composed of a non-magneticmaterial such as Al₂O₃ and may be deposited by any suitable depositionmethod such as CVD, PVD, ionized PVD, ion beam deposition (IBD), atomiclayer deposition (ALD), or any available deposition technology designedto fill high aspect ratio vias. The pitch of these discrete columns isdictated by the ability of the deposition technology to fill in thecavities between columns with no defect, and is investment-driven ratherthan technology-advancement driven. As a process module, process method700 can be readily inserted into the process flow at appropriatelocations where insert is functionally desired.

In summary, a magnetic head having a discontinuous array of columns isdisclosed. The columns may be disposed above or below a write pole. Thecolumns may be composed of a stiff material having low CTE for themanagement of PTR, and the discontinued width at the ABS may helpreducing compressive stress that may cause pole erasure.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

What is claimed is:
 1. A magnetic head, comprising: a discontinuousarray of columns; a dielectric material disposed between and over thediscontinuous array of columns; a read head disposed over the dielectricmaterial, and a write head disposed over the read head.
 2. The magnetichead of claim 1, wherein each of the columns comprises a materialselected from the group consisting of silicon carbide, tungsten andcombinations thereof.
 3. The magnetic head of claim 2, wherein thediscontinuous array of columns are aligned in a cross-track directionand each of the columns has a cross section parallel to an air bearingsurface and a length perpendicular to the air bearing surface.
 4. Themagnetic head of claim 3, wherein the cross section of each of thecolumns has a width and a thickness and the length is greater than thewidth or the thickness.
 5. The magnetic head of claim 3, wherein thedielectric material comprises alumina.
 6. A method for forming amagnetic head, comprising: depositing a write pole over a substrate;depositing an insert layer over the write pole; removing portions of theinsert layer to form a discontinuous array of columns; and depositing afill material between the discontinuous array of columns.
 7. The methodof claim 6, wherein the insert layer comprises a material selected fromthe group consisting of silicon carbide, tungsten and combinationsthereof.
 8. The method of claim 6, wherein the insert layer is depositedby physical vapor deposition.
 9. The method of claim 6, wherein the fillmaterial is deposited by chemical vapor deposition.
 10. The method ofclaim 6, wherein the portions of the insert layer are removed byreactive ion etching.
 11. A magnetic head, comprising: a write poleextending to an air bearing surface; and a discontinuous array ofcolumns aligned in a cross-track direction and disposed over the writepole, wherein each of the columns has a length extending perpendicularto the air bearing surface and a width, and wherein the length isgreater than the width, and wherein an insulating material is depositedbetween and over the discontinuous array of columns.
 12. The magnetichead of claim 11, wherein each of the columns comprises a materialselected from the group consisting of silicon carbide, tungsten andcombinations thereof.
 13. The magnetic head of claim 11, wherein each ofthe columns has a thickness that is less than the length, and whereinthe thickness and the width form a surface recessed from the air bearingsurface.
 14. The magnetic head of claim 11, further comprising anon-magnetic layer disposed between the write pole and the discontinuousarray of columns.
 15. The magnetic head of claim 14, wherein thenon-magnetic layer comprises alumina.